K 2013 WRAP UP: RECYCLING

Efficient degassing for highly contaminated and heavily printed plastic waste

Starlinger recycling technology has developed the new C-VAC degassing module for their recycling lines to enhance process engineering especially in the areas of filtration, degassing, and compounding.

The new C-VAC module is an integrated but independent extrusion module which can be added to every Starlinger recoSTAR recycling extruder. By using a main extruder plus the C-VAC module with degassing extruder and two degassing ports – the first one for reverse venting – superior degassing performance is achieved. Due to the two separate extruder drives, the extruder speeds can be adjusted independently from each other according to material requirements, resulting in lower shear and consequently better degassing efficiency. The short extruder lengths allow gentle processing of materials without significant shear, guaranteeing high-quality output even at low melt temperatures. The melt filter before the C-VAC module also increases filtration efficiency regarding organic contaminants.

The two degassing ports ensure good degassing. While the first port at the entrance of the degassing extruder is used for reverse venting against the melt flow, the remaining volatile contaminants are removed in melt flow direction at degassing port number two. A specially designed melt discharge from the main extruder to the degassing extruder divides the melt stream in several smaller streams, which results in more melt surface area – an increase by 300 per cent – and consequently better venting.

The Starlinger recycling lines equipped with C-VAC are especially suitable for materials which tend to create gases in the recycling process such as post-consumer household waste and agricultural film or highly printed film.

Starlinger (Greenville, S.C.);

www.starlinger.com; 864-297-900

Backflush screen changer meets recycling demands

New from Maag Automatik Inc., the CSC-BFX backflush screen changer is intended to satisfy all the demands of direct recycling (such as rPET bottle flakes to films) with just two screen pistons.

The recycling industry is increasingly demanding suitable backflush filters for direct processing of recycling material into 1A products (film, fibre, sections, et cetera) without the intermediate step of pelletizing – and the CSC-BFX backflush screen changer meets those requirements by storing the backflush material in rheologically optimized conditions in an integrated melt accumulator. In so doing the CSC-BFX cleans the contaminated screen surfaces with no impact on the end-product.

The backflush filter incorporates only two turn/lift cylinders for the complete filter function – as opposed to other designs with as many as eight hydraulic cylinders – making it compact and easy to integrate into existing extrusion lines with corresponding cost benefits.

The backflush screen changer is fully automatic. Its controller, the maaxBFX, provides user-friendly control, monitoring and visualization of operating parameters when handling highly contaminated polymer melt.

Extensive practical trials have been completed, and the backflush screen changer is available now in the standard extrusion sizes with active filter areas from 250cm² to 3,250 cm².

Maag Automatik Inc. (Charlotte, N.C.);

www.maag.com; 704-716-9026

Efficient shredding of wide range of plastics 

New from Vecoplan LLC, the V-ECO 1700 shredder is designed for companies that want to reuse their material coming out of the production, as well as plastic recyclers that are focused on efficient shredding in the most economical way.  

The machine optimizes the cutters and the counter knifes to deliver a homogenous particle structure combined with high throughput and less wear. The cutters are usable four times and are easy to change.

The frequency controlled motor transfers the entire torque from the motor over a belt to the rotor. The high performance and energy saving drive concept is flexible on speed and is well secured on tramped material, the company said. The new rotor design, in a W-shape, is well-suited for shredding various kinds of plastic materials such as film, mixed plastics, containers, textiles and many more.

The machine floor is designed to lift-up and the screen basket to swing down for good accessibility. Tramped materials are easy to remove, counterknives and cutters are easy to change, and the screen size is changeable within minutes.

The frequency controlled ram supports the efficient shredding processes and is easy to adopt if the infeed material changes.

Vecoplan LLC (Archdale, N.C.);

www.vecoplanllc.com; 336-861-6070

  Greg Parent; 416-678-0154 

Energy-efficient recycling system

Erema Plastic Recycling Systems launched the new Intarema plastic recycling and extrusion system at K 2013, designed to maximize productivity and offer flexibility and easy operation along with considerably lower energy consumption.

The Intarema system features the company’s Counter Current system in the border area of the cutter/compactor and tangentially connected extruder. As a result, the company said, the extruder can handle more feed material in less time. The company said the inverse tangential configuration of the Counter Current system ensures that the extruder screw is filled virtually pressure-free with the preheated material.

The new system offers flexibility when processing materials with particularly high input moisture and contamination levels, such as washed agricultural films, washed postconsumer film flakes (PE-LD, PE-LLD, PE-HD), films with solid content such as paper, wood or metals and also thick-walled regrind materials from waste automobile and electronic goods, PS cups and PE lids.

The system also features the company’s “Smart Start” concept, allowing many central process steps to run automatically, Erema said. Operators can also save all settings and parameters for the optimum result of a special recycling application under one “recipe name” and call it up through the push of a button.
 
Intarema systems are also equipped with EcoSave technology designed to offer reduced energy consumption, a reduction in CO2 emissions and lower production costs.

Intarema recycling systems are offered in three series: The T series features a short single-screw extruder without degassing and is designed for such materials as nonprinted edge trim, cutting waste, rolls and loose leftover film and regrind materials; the TE series features double degassing for the processing of slightly printed production or industrial waste plus fibers and technical plastics; and the TVEplus extruder system is designed for the recycling of materials that are difficult to process such as heavily printed films or very moist materials. This is made possible through ultrafine filtration, thorough melt homogenization and high-performance degassing in a single step.

Erema North America Inc. (Ipswich, Mass.);

www.erema.at; 978-356-3771

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New “open hearted” shredder design

At K 2013, Rapid Granulator showcased its new Raptor Series, positioned as a complementary range to the existing GranuMATIC-Series that will fill a number of current application gaps. Leveraging Rapid’s recent acquisition of shredder manufacturer Republic Machine, the series incorporates Republic’s PowerWedge rotor, which is said to be particularly well-suited to shredding and recycling of film and monofilament.

The Raptor Series also incorporates what the company calls an “open hearted design” – “In less than 70 seconds you can open up the whole shredder with the integrated hydraulic system and get direct access to all core components in the machine which drastically simplifies cleaning, service and maintenance,” the company said.

The new Raptor Series will initially be based on five models. All will be modular based and can therefore be tailored for the specific application. The first models will be available during Q1 2014, with the concept being on show at K. Shredding or airbag materials is another challenging task that these shredders are reported to be suitable for.

Rapid Granulator Inc. (Cranberry Township, Pa.);

www.rapidgranulator.com; 724-584-5220

  Dier International Plastics; (Unionville, Ont.); 416-219-0509

New PET recycling process should deliver significant savings

Recycling system supplier NGR Next Generation Recycling announced plans to move ahead into liquid state polycondensation (LSP) as a means of recycling of industrial and post consumer PET materials.

NGR is currently operating a pilot plant with capacity of 380 kg/hour to validate the process. Field testing of the process will start early next year, with full commercial deployment of the process expected in the first quarter of 2015, the company said.

The LSP process supports the processing of PET from industrial waste, including fibers, bottles, preforms, and films, as well as washed PET post-consumers flakes.

NGR is currently seeking regulatory approval for food grade applications with the relevant authorities, and expects the process to be a formality.

NGR Next Generation Recycling Machines Inc. (Norcross, Ga.);

www.ngr.at; 678-720-9861

  Auxiplast Inc. (Ste-Julie, Que.); 450-922-0282